Vent adapter for lead-acid battery systems

ABSTRACT

A vent adapter for a lead-acid battery includes a first side configured to mate with a vent port of the lead-acid battery via a first connector having a first geometry; and a second side in fluid communication with the first side and configured to mate with a vent passage of an automobile via a second connector having a second geometry, wherein the first and second geometries have respective shapes that are different from one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/260,047entitled “VENT ADAPTER FOR LEAD-ACID BATTERY SYSTEMS,” filed Jan. 28,2019, now U.S. Pat. No. 10,804,514, which is a division of U.S.application Ser. No. 14/337,479, entitled “VENT ADAPTER FOR LEAD-ACIDBATTERY SYSTEMS,” filed Jul. 22, 2014, now U.S. Pat. No. 10,193,113issued Jan. 29, 2019, which claims priority from and the benefit of U.S.Provisional Application Ser. No. 61/858,370, entitled “BATTERY VENT PORTDESIGNS,” filed Jul. 25, 2013, each of which is incorporated byreference herein in their entirety for all purposes.

BACKGROUND

The present disclosure relates generally to the field of batteries andbattery modules. More specifically, the present disclosure relates tobatteries that may be used in vehicular contexts, as well as otherenergy storage/expending applications.

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present disclosure,which are described and/or claimed below. This discussion is believed tobe helpful in providing the reader with background information tofacilitate a better understanding of the various aspects of the presentdisclosure. Accordingly, it should be understood that these statementsare to be read in this light, and not as admissions of prior art.

Batteries, as they are used today, come in a variety of forms. Frompacks of alkaline batteries purchased at supermarkets to large banks ofelectrochemical cells capable of powering houses or even spacecrafts,batteries can differ in shape, size, electrical characteristics, and soforth. The ubiquity of batteries as power storage devices is owed, atleast in part, to the ability of batteries to be connected to oneanother in a variety of ways to achieve different power profiles, theirscalability, and the reliable nature of the electrochemical cell as apower storage and retrieval solution.

As one specific example, lead-acid batteries have been used for decadesin vehicles, and a number of different shapes and sizes have beendeveloped for such batteries in an effort to meet certain power andspatial requirements. Despite these differences in size, shape, andpower ratings, many lead-acid batteries include similar features. Forexample, lead-acid automotive batteries generally include two or moreterminals, are generally connected to the same types of components(e.g., alternator, starter), and generally operate on the sameelectrochemical principles (the redox reactions of lead).

Because of the wide applicability and associated variation in sizes,shapes, and power ratings of batteries, consumers (e.g., distributors,storefronts, auto shops) must ensure that a particular battery meets therequirements of a particular application. For example, a person wantingto replace their vehicle battery must ensure that the replacementbattery matches the appropriate specifications established for theirvehicle. For this reason, there are a number of standards that specifycertain aspects of lead acid batteries (and other standards that may beassociated with other types of batteries). These standards enable bothmanufacturers and consumers to determine whether a particular battery isappropriate for a particular application. For example, the standards mayestablish limits, ranges, tolerances, etc., for lead-acid batteriesrelating to dimensions of the battery's housing, number and arrangementof electrochemical cells, the terminals (e.g., locations, shape, andsize), the battery's cold cranking performance and charge retention, andhow the battery may be retained within the vehicle, among others. Asnon-limiting examples, standards widely accepted and understood forautomobiles and other vehicle applications include Battery CouncilInternational (BCI) group numbers, Deutsche Industrie Normen (DINcodes), and European Norm (EN) codes. Each of these group numbers orcodes may be considered to specify a particular set of requirements fora lead-acid battery.

While these standards are very helpful to ensure the compatibility of aparticular battery with a particular application, this not only requiresthe purchaser to seek out a particular type of battery (e.g., a batterythat accords with a BCI, DIN, and/or EN number), but also typicallyrequires the point-of-purchase to carry a large stock of differentbattery types. For instance, an automotive specialty store might stocklarge quantities of batteries of varying group number requirements tomeet the needs of various consumers.

In accordance with an aspect of the present disclosure, it is nowrecognized that it may be desirable to meet a variety of applicationrequirements using a reduced number of battery types. Indeed, it is alsorecognized that it may be desirable for a single battery type to becompatible with multiple battery type applications.

SUMMARY

Certain embodiments commensurate in scope with the originally claimedsubject matter are summarized below. These embodiments are not intendedto limit the scope of the disclosure, but rather these embodiments areintended only to provide a brief summary of certain disclosedembodiments. Indeed, the present disclosure may encompass a variety offorms that may be similar to or different from the embodiments set forthbelow.

The present disclosure relates to batteries and battery modules. Morespecifically, the present disclosure relates to lead-acid battery ventadapter components and systems.

For example, in one embodiment, a vent adapter for a lead-acid batteryincludes: a first side configured to mate with a vent port of thelead-acid battery via a first connector having a first geometry; and asecond side in fluid communication with the first side and configured tomate with a vent passage of an automobile via a second connector havinga second geometry, wherein the first and second geometries haverespective shapes that are different from one another.

As another example, in an embodiment, a battery system includes alead-acid battery comprising: a housing; a plurality of lead-acidbattery cells disposed within the housing; and a vent port in thehousing configured to vent gases evolved from the plurality of lead-acidbattery cells; and a vent adapter configured to fluidly couple the ventport with a vent connector having a different geometric shape,comprising: a first connector substantially matched in shape and sizewith the vent port to enable an interference fit between the vent portand the first connector; and a second connector having a different shapethan the vent port of the lead acid battery.

As a further example, in another embodiment, a system includes alead-acid battery installed within a vehicle, comprising: a housing aplurality of lead-acid battery cells disposed within the housing andbeing electrically coupled to the vehicle via two or more terminals ofthe lead-acid battery; and a vent port in the housing, the vent portbeing fluidly coupled to a vent passage of the vehicle via a ventadapter, wherein the vent adapter is directly coupled to the vent portat a first end and is directly coupled to the vent passage of thevehicle at a second end, and the first and second ends of the ventadapter have different geometric shapes.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of a vehicle having a battery systemcontributing all or a portion of the power for the vehicle, inaccordance with an embodiment of the present approach;

FIG. 2 is a schematic representation of an embodiment of a lead-acidbattery having one or more vent ports that may be used in combinationwith a vent adapter, the vent adapter being configured to adapt thegeometry of the vent ports for use in an otherwise incompatibleapplication in accordance with an embodiment of the present approach;

FIG. 3 is a representation of an embodiment of a Battery CouncilInternational (BCI) group 65 lead-acid battery and an embodiment of themanner in which the vent port of the group 65 lead-acid battery maybeadapted for use in a BCI group 66 application using an adapterconfigured in accordance with certain aspects of the present disclosure;

FIG. 4 is a perspective view of an embodiment of the adapter of FIG. 3 ,in accordance with certain aspects of the present disclosure;

FIG. 5 is a front view of the embodiment of the adapter of FIG. 4 , inaccordance with certain aspects of the present disclosure;

FIG. 6 is a side view of an embodiment of the adapter of FIGS. 4 and 5 ,in accordance with certain aspects of the present disclosure;

FIG. 7 is a cross-sectional side view of an embodiment of the adapter ofFIGS. 4-6 , in accordance with certain aspects of the presentdisclosure;

FIG. 8 is a representation of an embodiment of a BCI group 24F lead-acidbattery and an embodiment of the manner in which the vent port of thegroup 24F lead-acid battery maybe adapted for use in combination withkeyed vent tubes using an adapter configured in accordance with certainaspects of the present disclosure;

FIG. 9 is a front view of the embodiment of the adapter of FIG. 8 , inaccordance with certain aspects of the present disclosure;

FIG. 10 is a side view of the embodiment of the adapter of FIG. 8 , inaccordance with certain aspects of the present disclosure;

FIG. 11 is a cross-sectional side view of the embodiment of the adapterof FIG. 8 , in accordance with certain aspects of the presentdisclosure;

FIG. 12 is a schematic representation of the manner in which an adapterconfigured in accordance with certain aspects of the present disclosuremay be used to adjust a venting position of a bank of BCI group 31lead-acid batteries used in commercial applications; and

FIG. 13 is an expanded view of a portion of the schematic representationof FIG. 12 including the adapter.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effortto provide a concise description of these embodiments, not all featuresof an actual implementation are described in the specification. Itshould be appreciated that in the development of any such actualimplementation, as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the presentdisclosure, the articles “a,” “an,” and “the” are intended to mean thatthere are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features.

As set forth above, there are a number of accepted standards thatspecify certain aspects of lead-acid batteries, including but notlimited to Battery Council International (BCI) group numbers, DeutscheIndustrie Normen (DIN) codes, European Norm (EN) codes, JapaneseIndustry Standard (JIS) codes, Society of Automotive Engineers (SAE)designations, and so forth. Further, there may be a number of otherfeatures of lead-acid batteries that are not necessarily controlled bythese standards, but, by virtue of the constraints on manufactureassociated with the group requirements, are generally associated with aparticular location on the batteries, and may generally be associatedwith a particular size and/or shape.

While manufacturing, stocking, and selling these different sizes ofbatteries enables manufacturers and storefronts to provide batteries fora wide variety of applications, it is now recognized that it may bedesirable to enable greater flexibility for particular types ofbatteries (e.g., lead-acid automotive batteries) to be suitable for anumber of different applications. For example, it is now recognized thatenabling compatibility between batteries meeting certain standards thatare sufficiently close from a power and spatial (e.g., form factor)standpoint may reduce the number of batteries that need to bemanufactured, stocked, and sold, thereby increasing manufacturethroughput and greater consumer confidence.

In accordance with the present disclosure, for example, it is nowrecognized that a first lead-acid battery type may be used in place ofanother lead-acid battery type using one or more adapter features (e.g.,a vent adapter) coupled to the first lead-acid battery type, where theone or more adapter features are configured to mimic a structuralfeature (e.g., a vent port) of the second battery type by changing thegeometry (shape) of the structural feature. For example, the dimensionsand power performance of two different lead-acid battery types belongingto different group standards may be similar, but they may have one ormore features (e.g., connectors, protrusions, hoses) that are different.One such feature may include the vent ports of the different lead-acidbattery types, where the different vent ports enable the release of ventgases from their respective battery, but are different in configuration(e.g., shape, size). In accordance with an aspect of the presentdisclosure, an adapter may have a first portion configured to interfacewith a vent port of a first battery type, the vent port having a firstgeometry (shape and size), and may have a second portion having a secondgeometry different from the first and having substantially the sameconfiguration (e.g., geometry, dimensions) as a vent port of a secondbattery type. In this way, when the adapter is coupled to the vent portof the first battery type, the resulting configuration (e.g., vent portshape) is as if the second battery type were present, and variousventing features of the application (e.g., vent hoses) may be connectedthereto. Specific examples of battery groups and associated adapters arediscussed in further detail below.

For example, in one aspect of the present disclosure and as discussed indetail below with respect to FIGS. 3-7 , batteries that are suitable forBCI group 65 applications, referred to herein as group 65 batteries, andbatteries that are suitable for BCI group 66 applications, referred toherein as group 66 batteries, have dimensions (length, width, height)that are substantially the same. Specifically, BCI group 65 and 66dimensional requirements only differ by approximately 2 millimeters inone direction (i.e., in their height), and the power requirements of BCIgroups 65 and 66 substantially overlap from a cold cranking performanceand capacity standpoint. However, their vent ports have a differentshape and size. It is now recognized that an adapter may be placed ontothe group 65 battery's vent port to enable the group 65 battery to ventas if it were a group 66 battery, where the adapter results in a changein the shape (i.e., more than simply a change in size) of the vent port.

In another aspect of the present disclosure and as discussed in detailbelow with respect to FIGS. 8-11 , batteries that are suitable for BCIgroup 24F applications, referred to herein as group 24F batteries, maybe fitted with an adapter to enable the group 24F battery to becompatible with other vent designs, such as locking key vent designs. Inthis respect, it is now recognized that, generally, group batteriescompatible with other applications but for their vent design (vent portsize and shape) may be fitted with specially-configured adapters toenable the use of the group batteries in the other applications.

In a further aspect of the present disclosure and as discussed in detailbelow with respect to FIGS. 12 and 13 , batteries that are suitable forBCI group 31 applications, referred to herein as group 31 batteries, maybe fitted with an adapter to enable the group 31 battery to vent at analternative location. Indeed, it is now recognized that the ventposition, vent shape, and vent size of a particular group battery may beadjusted using the type of adapters described herein. Discussed beloware example implementations of batteries subject to the embodimentsdescribed herein, as well as a brief description of various aspects oflead-acid batteries that are pertinent to the present disclosure.

Referring to FIG. 1 , a perspective view of a vehicle 10 is provided,which includes a number of possible locations for one or more batteries12 subject to the present embodiments. In accordance with presentembodiments, the vehicle 10 may be any type of vehicle that utilizes abattery that vents, including but not necessarily limited to lead-acidbatteries. Indeed, the vehicle 10 is intended to represent any numberand variety of vehicles that may utilize venting batteries. While thepresent embodiments are described in the context of lead-acid batteriesconforming to a particular standard (e.g., BCI, DIN, EN, SAE, JIScodes), they are also intended to apply to any type of battery and anytype of vehicle or other application.

As depicted, the one or more batteries 12 may be positioned at differentlocations within the vehicle 10. For instance, a first battery 14 may belocated at a forward section of the vehicle 10 underneath a hood 16, asecond battery 18 may be located underneath a front seat 20, such as apassenger seat, or a third battery 22 may be located underneath a rearseat 24 or within a trunk 26 of the vehicle 10. While the terms “first,”“second,” and “third” are used herein, this is only to facilitatereference to the different possible battery locations. Indeed, it iswithin the scope of the present disclosure for the vehicle 10 to onlyinclude, as an example, the second battery 18 underneath the front seat20. As another example, it is within the scope of the present disclosurefor the vehicle 10 to only include the third battery 22 underneath therear seat 24 or within the trunk 26. Any combinations and locations ofdifferent batteries are therefore encompassed by the present disclosure.

In accordance with an aspect of the present disclosure, any one or acombination of the first, second, or third batteries 14, 18, 22 may befitted with an adapter to enable them to be used in the vehicle 10. Forinstance, the first, second, or third batteries 14, 18, 22 may havecertain structural features (e.g., vent ports) that are not compatiblewith their desired placement within the vehicle 10 (e.g., do not have acompatible shape and size with corresponding connectors of the vehicle10). In one embodiment, an adapter may be fitted onto the first, second,or third batteries 14, 18, 22 to enable them to properly interface withcorresponding vehicle components.

An example embodiment of one of the batteries 12 is depicted in FIG. 2 .In particular, the battery 12 shown in the perspective view of FIG. 2 isintended to represent a lead-acid battery that may include any number oflead-acid electrochemical cells connected to one another in anyconfiguration. That is, the battery 12 of FIG. 2 may have any voltageand any capacity suitable for any lead-acid battery application. Morespecifically, the battery 12 may be a battery suitable for a particularBCI group application, but not necessarily suitable for other BCI groupapplications due to incompatible structural and/or power componentfeatures.

The illustrated battery 12 includes two terminals 28, including a firstterminal 30 (e.g., a positive terminal) and a second terminal 32 (e.g.,a negative terminal), though other embodiments of the battery 12 mayinclude more than two terminals 28. The terminals 28 are illustrated asbeing cylindrical, but may generally be of any form and size. Forexample, the terminals 28 may include, but are not limited to, SAEposts, DIN posts, EN/JIS posts, JIS pencil posts, threaded posts, flatterminals having different shapes, and the like, or any combinationthereof. The terminals 28, in general, are electrically connected to atleast one lead-acid electrochemical cell (also referred to as lead-acidbattery cells, lead-acid cells, and the like), for example to positiveand negative plates of the same or different lead-acid electrochemicalcells. The terminals 28 enable the battery 12 to provide power to one ormore components of the vehicle 10 by enabling a physical connection tocorresponding connectors of the vehicle 10.

The battery 12 also includes a housing 34, which may be of any geometryand dimensions in accordance with any BCI group, EN, JIS, or DINstandard, or any other standard. As depicted, the housing 34 includes abody 36, which houses various internal components such as the lead-acidelectrochemical cells, electrochemical cell interconnects, and otherelectrical and/or mechanical components. The housing 34 also includes acover 38 positioned atop the body 36 in the illustrated configuration,though the cover 38 may have a different relative position depending onthe arrangement of the battery 12 within the vehicle 10 (e.g., on itsside). The cover 38 may be secured to the body 36 via any appropriatetechnique, such as snap-fitting, welding (e.g., ultrasonic, laser),adhesives, sealants, and so forth. The housing 34 of the battery 12 willgenerally determine the form factor of the battery 12, while theelectrochemical cells determine the power performance of the battery 12.

In this regard, the battery 12 may be any lead-acid battery type,including a flooded battery or a valve-regulated lead-acid (VRLA)battery, and the difference between these may be better appreciated withreference to their operation. As may be appreciated, all lead-acidbatteries include lead-acid electrochemical cells, which each include apositive plate and a negative plate. The plates each include lead (Pb),and generally differ in terms of how much lead is present in itsdifferent oxidation states (Pb(s), Pb²⁺, and Pb⁴⁺). The electrochemicalreactions of lead in the battery 12 are facilitated using aqueoussulfuric acid (H₂SO₄(aq)) as an electrolyte.

One difference between flooded lead-acid batteries and VRLA batteries isthat the sulfuric acid is less mobile and therefore less likely to spillin VRLA batteries. VRLA batteries may be of two different types,including gelled electrolyte (gel) and absorbed glass mat (AGM)batteries. Gelled electrolyte batteries generally include a solid (e.g.,silica, SiO₂) mixed with the sulfuric acid, and AGM batteries generallyinclude a separator (e.g., a fiberglass mat) wrapped around one of theplates (generally the positive plate), and the mat includes a high levelof absorbance of the sulfuric acid electrolyte used in theelectrochemical cells. For this reason, gel and AGM batteries may beplaced in a number of orientations without losing significant amounts ofwater as a result, while flooded batteries are generally maintained inan upright position.

Some of the electrochemical reactions during charging and/or dischargingof all of the lead-acid batteries may evolve gases, such corrosivegases, hydrogen (H₂), and oxygen (O₂). Indeed, if the battery isovercharged, hydrogen and oxygen may be generated from the electrolysisof water. Thus, if this gas evolution remains unmitigated, all lead-acidbatteries will lose water.

In this regard, another difference between flooded and VRLA batteries isthat VRLA batteries generally include features configured to enablerecombination of the hydrogen with oxygen at the negative plate, whichreplenishes water that would otherwise be lost to the battery byventing. For example, a VRLA battery may include a one-way pressurerelief valve that enables the battery 12 to hold a pressure sufficientto encourage recombination of the oxygen and hydrogen at the negativeplate. Flooded lead-acid batteries, on the other hand, may generallyrequire refilling with water as a regular maintenance procedure becausethis one-way valve, and associated regeneration of water, may not bepresent.

The reaction to regenerate the water in VRLA batteries is commonlyreferred to as a recombination reaction. However, at times, thegeneration of the gases may be faster than the recombination reaction,which may cause pressure buildup and opening of the one-way valve. Thismeans that the VRLA batteries may also lose some amount of water due toassociated venting of hydrogen and oxygen. Thus, essentially everylead-acid battery may undergo at least some venting, and for thisreason, the battery 12 will essentially always include some sort of ventport 40 configured to enable the venting of gases and thereby mitigatedamage to the battery 12. Aspects of the present embodiments aredirected toward the adaptation of the vent port 40 for different batteryapplications (e.g., different group applications).

The cover 38 may include one or more of the vent ports 40, which areillustrated as vent holes but may be protrusions or any otherappropriate venting feature. In certain configurations, the battery 12may also include a base 42 that is separate from the body 36 of thehousing 34, and which may also be of any geometry and dimensions. Thebase 42 may have the same or different dimensions relative to the body36 and the cover 38. Further, in certain embodiments, the base 42 may bereferred to as a hold-down feature of the battery 12, which enables thebattery 12 to be secured in its location within the vehicle 10. In someembodiments, the base 42 may be separate from the battery 12, and maynot necessarily be present. In other words, in some embodiments, thebattery 12 may not include the base 42, and the bottom of the battery 12may instead correspond to a surface of the body 36 (e.g., opposite thecover 38).

Together, the cover 38, the body 36, and, when present, the base 42 ofthe housing 34 determine a height 44, a length 46, and a width 48 of thebattery 12. In one aspect of the present disclosure, the height 44, orthe length 46, or the width 48, or any combination thereof, may complywith one or more battery group standards set forth in, for example, BCI,DIN, EN, SAE, or JIS codes. In certain aspects of the presentdisclosure, for example, the height 44, the length 46, the width 48, andthe other components of the battery 12 may comply with BCI group 65,24F, or 31 standards, but may be sufficiently close to other BCI groupstandards. In accordance with certain embodiments, the group 65 battery,group 24F battery, or group 31 battery may be fitted with a vent portadapter 50 configured to enable the particular battery to be used in agreater number of applications than would otherwise be appropriate.

The term “applications,” as used herein, is intended to denoteapplications where a particular set of standards have been establishedand that are met by a particular group of batteries. For example, agroup 65 battery may be considered to meet a group 65 application, agroup 24F battery may be considered to meet a group 24F application, anda group 31 battery may be considered to meet a group 31 application,where the group notations are established by the BCI group numberassociated with the particular designation. Thus, in accordance with anaspect of the present embodiments, the adapter 50 enables, for example,a group 65 battery to be compatible with group applications other thangroup 65 applications, such as group 66 applications.

The adapter 50 may similarly enable compatibility between other batterygroups and group applications, depending on its particular configuration(e.g., geometry, dimensions). Whether a particular group battery may befitted with an adapter to enable compatibility with other groupapplications is dependent upon, among other things, the dimensions(e.g., size, form factor) of the battery 12, the number, size, andarrangement of its lead-acid electrochemical cells, its terminallocations and shape, vent port sizes, shapes, and locations, and thecorresponding requirements of the group application in question. Indeed,as noted above, BCI group 65 and 66 dimensional requirements only differby approximately 2 millimeters in one direction (i.e., in their height),and the power requirements of BCI groups 65 and 66 substantially overlapfrom a cold cranking performance and capacity standpoint. One maindifference between these groups that prevents their inherentcompatibility is the particular configuration (shape, size) of theirvent ports. As set forth in further detail below with respect to FIGS.3-7 , certain embodiments of the adapter 50 overcome this limitation.

As will be appreciated, the Battery Council International (BCI) is atrade association that sets certain standards for vehicle batteries. Anumber of battery groups and sizes have been specified by the BCI. Whilethe present embodiments are applicable to all different standards,tabulated below are a number of specifications set forth for a varietyof BCI groups, which are provided herein for reference. Further, to theextent that the values set forth below may not agree with the standardsspecified by the BCI, the BCI (or other) standards are incorporatedherein by reference in their entirety. Additional information regardingBCI battery standards, technical specifications and replacement isavailable in the BCI Battery Technical Manual and the BCI BatteryReplacement Data Book, both available from BCI of Chicago, Illinois. Inregard to Table 1 below, it is within the scope of the presentdisclosure for an adapter configured in accordance with any one or acombination of the embodiments described herein to be used with any oneor a combination of the listed group numbers. Specifically, adapters 50configured in accordance with present embodiments may be used to renderany one or a combination of the BCI group batteries set forth belowsuitable for use in another BCI group number application, provided thatthe dimensions and power requirements of one BCI group number (e.g., afirst group designation) and the other BCI group number (e.g., a secondgroup designation) and are sufficiently compatible.

As discussed herein, in some embodiments, adapters 50 in accordance withpresent embodiments may be used when the first and second groupdesignations have dimensions that differ by no more than 10% in thelength, width, and/or height direction. For example, the groupdesignations may have dimensions that differ by between approximately10% and approximately 0.1% in the length, width, and/or heightdirection. However, to the extent that the group designations includemaximum dimensional requirements, it should be noted that, in otherembodiments, a first battery having a first group designation may have amuch smaller form factor but may still be appropriate for a second groupdesignation, provided that the power specifications of the first batteryare sufficient for the power requirements of the second groupdesignation. In such embodiments, various housing size adapters, shims,and so forth may be used to more closely conform to existing mountingstructures. The adapter 50 of the present embodiments may be provided incombination with other such adapters, for example with a new battery, oras a kit. For instance, a kit may include the adapter 50 and a lead-acidbattery in combination for replacing an existing battery. Indeed,housing adapters and those of the present disclosure (adapters 50) maybe used in combination with lead acid batteries having an irregular(e.g., not polygonal) shape.

TABLE 1 Selected BCI Group Numbers and Associated Dimensional and PowerSpecifications O.E. Performance Ranges Cold Cranking Reserve PerformanceCapacity BCI Amps. @ Minutes @ Group Maximum Overall Dimensions 0° F.80° F. Number Millimeters Inches (-18° C.) (27° C.) It, 6 Cell) 21 208173 222 8 3/16 6 13/16 8 ¾ 305-420  50-70 21R 208 173 222 8 3/16 6 13/168 ¾ 310-490  50-70 22 F 241 175 211 9 ½ 6 15/16 8 5/16 230-500  45-9022HF 241 175 229 9 1/2 6 15/16 9 290  69 22NF 240 140 227 9 7/16 5 ½ 815/16 165-500  50-60 24 260 173 225 10 ¼ 6 13/16 8 ⅞ 200-900  50-95 24 F273 173 229 10 ¾ 6 13/16 9 250-710  50-95 24H 260 173 238 10 ¼ 6 13/16 9⅜ 325-410  70-95 24R 260 173 229 10 ¼ 6 13/16 9 550  70-95 241 260 173248 10 ¼ 6 13/16 9 ¾ 380-500 110 25 230 175 225 9 1/16 6 15/16 8 ⅞260-550  50-90 26 208 173 197 8 3/16 6 13/16 7 ¾ 245-525  50-80 26R 208173 197 8 3/16 6 13/16 7¾ 235-540  60-80 27 306 173 225 12 1/15 6 13/158⅞ 340-810 102-140 27 F 318 173 227 12 ½ 6 13/16 8 15/16 315-710  95-14027H 298 173 235 11¾ 6 13/16 9 ¼ 420-440 125 29NF 330 140 227 13 5 ½ 815/16 300-430  95 33 338 173 238 13 5/16 6 13/16 9 ⅜ 1050 165 34 260 173200 10 ¼ 6 13/16 7 ⅞ 375-800 100-115 34R 260 173 200 10 ¼ 6 13/16 7 ⅞450-700 110 35 230 175 225 9 1/16 6 15/16 8 ⅞ 310-640  80-110 36R 263183 206 10 ⅜ 7 3/16 8 ⅛ 540-650 130 40R 278 175 175 11 6 15/16 6 15/16590-650 110-120 41 293 175 175 11 9/16 6 15/16 6 15/16 300-720  65-95 42242 175 175 9 9/16 6 15/16 6 15/16 210-650  65-95 43 334 175 205 13 ⅛ 615/16 8 1/16 375-495 115 45 240 140 227 9 7/16 5 ½ 8 15/16 400-500 60-80 46 273 173 229 10 ¾ 6 13/16 9 315-450  75-95 47 242 175 190 99/16 6 15/16 7 ½ 290-650  75-85 48 278 175 190 11 6 15/16 7 ½ 315-770 85-95 49 353 175 190 13 15/16 6 15/16 7 ½ 470-950 140-150 50 343 127254 13 ½ 5 10 500-600  85-100 51 238 129 223 9⅜ 5 1/16 8 ¾ 270-435  7051R 238 129 223 9 ⅜ 5 1/16 8 ¾ 310-435  70 52 186 147 210 7 5/16 5 13/168 ¼ 405  70 53 330 119 210 13 4 11/16 8 ¼ 210-315  40 54 186 154 212 75/16 6 1/16 8 ⅜ 305-330  60 55 218 154 212 8 9/16 6 1/16 8 ⅜ 370-420  7556 254 154 212 10 6 1/16 8 ⅜ 350-505  90 57 205 183 177 8 1/16 7 3/16 615/16 310  60 58 255 183 177 10 1/16 7 3/16 6 15/16 245-540  75 58R 255183 177 10 1/16 7 3/16 6 15/16 540-580  75 59 255 193 196 10 1/16 711/16 7 ¾ 540-590 100 60 332 160 225 13 1/16 6 5/16 8 ⅞ 225-730  65-11561 192 162 225 7 9/16 6 ⅜ 8 ⅞ 310  60 62 225 162 225 8 ⅞ 6 ⅜ 8 ⅞ 310-450 75 63 258 162 225 10 3/16 6 ⅜ 8 ⅞ 450  90 64 296 162 225 11 ⅝ 6 ⅜ 8 ⅞475-535 105-120 65 306 192 192 12 1/16 7 9/16 7 9/16 600-850 130-165 66306 192 194 12 1/16 7 9/16 7 9/16 650-750 130-140 67R 231 175 176 9 ⅛ 615/16 6 15/16 390  65 70 208 180 186 8 3/16 7 1/16 7 5/16 250-525  60-8071 208 179 216 8 3/16 7 1/16 8 ½ 275-450  75-90 72 230 179 210 9 1/16 71/16 8 ¼ 275-430  60-90 73 230 179 216 9 1/16 7 1/16 8½ 425-500  80-11574 260 184 222 10 ¼ 7 ¼ 8 ¾ 265-550  75-140 75 230 180 186 9 1/16 7 1/167 5/16 245-690  90 76 334 179 216 13 ⅛ 7 1/16 8 ½ 750-1075 150-175 77306 184 222 12 1/16 7 ¼ 8 ¾ 350-465 107-110 78 260 180 186 10 ¼ 7 1/16 75/16 465-800 105-115 79 307 179 188 12 1/16 7 1/16 7 ⅜ 800-840 140 85230 173 203 9 1/16 6 13/16 8 430-630  90 86 230 173 203 9 1/16 6 13/16 8430-640  90 90 242 175 175 9 9/16 6 15/16 6 15/16 450-650  80 91 278 175175 11 6 15/16 6 15/16 520-700 100 92 315 175 175 12 7/16 6 15/16 615/16 575-720 130 93 353 175 175 13 15/16 6 15/16 6 15/16 600-800 15094R 315 175 190 12 7/16 6 15/16 7 ½ 620-790 135 95R 394 175 190 15 9/166 15/16 7 ½ 760-950 190 96R 242 175 175 9 ½ 6 15/16 6 15/16 500-590  9597R 252 175 190 9 15/16 6 15/16 7 ½ 575  90 98R 283 175 190 11 ⅛ 6 15/167 ½ 620-760 120 99 207 175 175 8 ⅛ 6 15/16 6 15/16 360  50 99R 210 175175 8 5/16 6 15/16 6 15/16 470  55-75 100 260 179 188 10 ¼ 7 1/16 7 ⅜770 115 101 260 179 170 10 ¼ 7 1/16 6 11/16 540 115 121R 208 177 215 8 ¼7 8 ½ 500-550  85 124R 262 177 218 10 ⅜ 7 8 ⅝ 500-660 110 151R 188 125225 7 7/16 4 15/16 8 ⅞ 270-335  55 Heavy-Duty Commercial Batteries (12Volt, 6 Cell) 4D 527 222 250 20 ¾ 8 ¾ 9 13/16 600-1200 225-325 6D 527254 260 20 ¾ 10 10 ¼ 750 310 8D 527 283 250 20 ¾ 11 ⅛ 9 13/16 700-1300235-465 28 261 173 240 10 ¼ 6 13/16 9 7/16 500  80-135 29H 334 171 23213 ⅛ 6 11/16 9 ⅛ 350-840 145 30H 343 173 235 13 ½ 6 13/16 9 ¼ 370-1025120-150 31A 330 173 240 13 6 13/16 9 7/16 660-1000 100-200 31T 330 173240 13 6 13/16 9 7/16 620-1980 100-200

It should be noted that the above listing is not exhaustive, and otherform factors and/or standards may be utilized. A number of variationsmay include, but are not limited to: rated voltages, capacity,application, the physical mounting requirements (which may vary fordifferent original equipment manufacturers), the terminal types andconfigurations, the country or region, and so forth. Terminals may beplaced, for example, in top, front, side or a combination of locations.Hold down ledges and features may similarly vary with the differentenclosures.

One particular application of the adapter 50 of the present embodimentsis depicted in FIG. 3 . Specifically, FIG. 3 is a perspective view of agroup 65 embodiment of the battery 12 (e.g., a first group applicationbattery), which includes at least one vent port 40 formed in the cover38 of the housing 34 on one of the sides of the battery 12. Asunderstood in the art, such a group 65 battery is, typically, only usedin group 65 applications. However, embodiments of the adapter 50,configured in accordance with the present disclosure, enable the battery12 of FIG. 3 to be used in group 66 applications as well (e.g., so as tobe compatible with a second group application).

In particular, the embodiment of the adapter 50 of FIGS. 4-7 , which isdescribed in further detail below, enables the vent port 40 of the group65 battery (e.g., the vent port 40 has a first geometry appropriate fora first group application) to be indirectly coupled to a vent hose 60(e.g., a vent passage) of a group 66 application, as shown in FIG. 3(e.g., a vent passage having a second geometry appropriate for a secondgroup application), by changing the geometry of the structure that isultimately fluidly coupled to the vent port 40.

Normally, the vent hose 60 of the group 66 application (e.g., the secondgroup application) is incompatible with the vent port 40, which has acircular geometry 62. Specifically, the group 65 battery as illustratedutilizes a DIN-style vent hole having a 6 mm diameter, and the vent hose60 is unable to couple with the vent port 40 in an appropriately matedrelationship. The adapter 50, as schematically illustrated in FIG. 4 ,inserts into the circular geometry 62 in a first mated relationship, andcouples with the vent hose 60 in a second mated relationship by way ofone or more features that substantially match the geometry of the venthose 60. In the schematic depiction of the adapter 50 in FIG. 3 , afirst protrusion 64 of the adapter 50 enables the first matedrelationship and a second protrusion 66 of the adapter 50 enables thesecond mated relationship.

The adapter 50 may have further refined aspects of the first and secondprotrusions 64, 66 to enable the first and second mated relationships tobe formed in a more secure fashion. The adapter 50 depicted in theperspective view of FIG. 4 , for example, includes a first side 70having a geometry that substantially matches the circular geometry 62vent port 40 of FIG. 4 (e.g., a DIN-style 6 mm vent hole), and a secondside 72 having a geometry that substantially matches the annular (orother) geometry of the vent hose 60. These sides generally correspond tothe first and second protrusions 64 and 66, respectively, and they alsogenerally have different geometries (shapes and sizes). Morespecifically, the first side 70 includes a vent port interface surface74 of a generally circular geometry and having an annular taper 76 suchthat the vent port interface surface 74 is generally frusto-conical inshape. The annular taper 76 may enable the adapter 50 to securely fitwithin the vent port 40, for example via a friction/interference fit. Inthis way, the annular taper 76 may taper the vent port interface surface74 from a first size (e.g., a first diameter) to a second size (e.g., asecond diameter), where the first size is smaller than or substantiallymatches the size of the vent port 40, and the second size issubstantially matched to or larger than the vent port 40 (e.g., has adiameter of approximately 6 mm). The annular taper 76 can also be seenin FIGS. 7 and 8 .

Generally, any point between the first and second diameters of theannular taper 76 may enable an interference fit with the vent port 40.However, in one embodiment, the adapter 50 includes an annular neckregion 78 of generally unchanging diameter extending from the annulartaper 76 and also having the second diameter. The annular neck region 78may enable the adapter 50 to have a greater surface area with which tointerface with the vent port 40, among other advantages. In certainembodiments, such as when the vent port 40 is sufficiently deformable(e.g., a softer material than the adapter 50), the second diameter maybe larger than the vent port 40 so as to enable a stronger interferencefit between the annular neck region 78 and the vent port 40.

Contrasting the second side 72 with the first side 70, the adapter 50includes a vent passage interface surface 80, which has a geometry thatsubstantially matches with the vent hose 60 (FIG. 3 ). In theillustrated embodiment, the vent passage interface surface 80 has anellipsoidal geometry having a size that enables the second side 72 to beinserted into and secured within the vent hose 60 (e.g., via aninterference fit). The vent passage interface surface 80 also includes ataper 82, which transitions the vent passage interface surface 80 from afirst respective geometry to a second respective geometry, the firstrespective geometry having a size that is smaller than, or substantiallymatched with, an internal geometry of the vent hose 60, and the secondrespective geometry having a size that is substantially matched with, orlarger than, the internal geometry of the vent hose 60.

Specifically, the first respective geometry may correspond to a frontface 83 of the adapter 50, and the second respective geometry maycorrespond to a lip portion 84 having a geometry that is larger than thevent hose 60 so as to resist retraction of the vent hose 60 away fromthe adapter 50. In other words, the lip portion 84 may act as a catch tomaintain connection between the adapter 50 and the vent hose 60. The lipportion 84 may be desirable in embodiments where the vent hose 60 issufficiently pliable so as to enable the lip portion 84 to protrude intothe thickness of the vent hose 60 and thereby act as a retentionmechanism.

An obround neck region 86 (e.g., an ellipsoidal region) joins theannular neck region 78 and the vent passage interface surface 80.Specifically, the obround neck region 86 has an outer geometry that issubstantially the same as the outer geometry of the front face 83. Thegeometry of the obround neck region 86 may be smaller than, orsubstantially matched to, the inner geometry of the vent hose 60.Further, the obround neck region 86 enables a greater surface area withwhich to contact or overlap with the vent hose 60, and also includes aninternal transition in venting geometry, which is described in furtherdetail below with respect to FIG. 7 .

A front view of the group 65 battery adapter 50 is provided in FIG. 5 .As shown, the changes in size at the second side 72 of the adapter 50,as well as the internal and external surfaces thereof, appear asconcentric ellipses having different minor and major diameters. Thedifferences in the venting geometries is also represented, and can bemore clearly seen in FIG. 7 , which is described in further detailbelow.

The view provided in FIG. 5 also shows the respective major and minordiameters of the second side 72 of the adapter 50. In particular, therespective minor and major diameters of the features positioned on thesecond side 72 of the adapter include minor and major diameters of innerand outer surfaces 90, 92 of the front face 83, and inner and outersurfaces 94, 96 of different portions of the vent passage interfacesurface 80. While not labeled in the drawing, the minor diameters may beconsidered to run top to bottom, and the major diameters may beconsidered to run left to right. As depicted, the inner surface 90tapers inward such that its minor and major diameters decrease in adirection moving from the second side 72 to the first side 70. In otherwords, a portion of a flow path of vented gases from the battery 12defined by the inner surface 90 increases in size in the direction ofvent flow.

FIG. 6 is a side view of the adapter 50 of FIGS. 3-5 . In particular,FIG. 6 depicts the side of the adapter 50 (the adapter is symmetrical sothat both sides are substantially the same), and various outer diametersassociated with the features described above with respect to FIG. 4 .Thus, as described herein with respect to FIG. 6 , all diameters areconsidered to be outer diameters. As shown from left to right, theannular taper 76 of the vent port interface surface 74 transitions thesurface 74 from having a first outer diameter 100 to a second outerdiameter 102, the second outer diameter 102 also corresponding to anouter diameter at the annular neck region 78. Due to this transition,the vent port interface surface 74 may be considered to have a rear face104 and an elbow portion 106 corresponding to the respective positionsof the first and second outer diameters 100, 102.

In some embodiments, the annular neck region 78 may have a third outerdiameter 108 that is smaller than the second outer diameter 102, forexample such that the second outer diameter 102 forms a lip that may beused as a retaining member as set forth above with respect to the lipportion 84. It should be noted, however, that any relative sizing of thesecond and third outer diameters is encompassed by the presentembodiments. Thus, the third outer diameter 108 may be substantially thesame size, larger than, or smaller than the second outer diameter 102,and may be substantially the same size, larger than, or smaller than thefirst outer diameter 100.

Moving now from right to left in FIG. 6 and referring to the second side72 of the adapter 50, as noted above, the taper 82 transitions the ventpassage interface surface 80 from the front face 83 having a firstrespective geometry to the lip portion 84 having a second respectivegeometry. Because the second side 72 of the adapter 50 has obround(e.g., elliptical) outer geometries, the vent passage interface surface80 and the obround neck region 86 have outer major and minor diameters,as discussed above with respect to FIG. 5 . In the illustrated sideview, only the minor diameters are labeled (the major diameters runcrosswise through the page). With this in mind, the taper 82 may beconsidered to transition the vent passage interface surface 80 from afirst minor outer diameter 110 to a second minor outer diameter 112,where the second is larger than the first. The second minor outerdiameter 112, again, may be substantially the same as, or larger than, aminor inner diameter of the vent hose 60 (FIG. 3 ), while the firstminor outer diameter 110 may be substantially the same as, or smallerthan, a minor inner diameter of the vent hose 60.

The obround neck region 86 includes a third minor outer diameter 114,which may have any relative size relationship to the second and thirdminor outer diameters 112, 114. In the illustrated embodiment, the thirdminor outer diameter 114 is substantially the same as the first minorouter diameter 110, and is smaller than the second minor outer diameter112. In certain embodiments, the third minor outer diameter 114 may besized to enable the obround neck region 86 to maintain an interferencefit with the vent hose 60. Further, it should be noted that the majorouter diameters of the obround (e.g., elliptical) portions of theadapter 50 may generally follow the minor outer diameters describedabove so as to maintain the geometrical relationships described above.

An embodiment of an internal vent path 120 formed by the inner surfacesof the adapter 50 is depicted in FIG. 7 , which is a cross-sectionalside view of the adapter 50. As shown, the internal vent path 120 isconfigured to flow vented gases from the battery 12 in a directiongenerally from the first side 70 to the second side 72. The illustratedinternal vent path 120 does not follow the geometrical relationships setforth above with respect to the outer surfaces of the adapter 50 (e.g.,the vent port interface surface 74 being tapered, the obround neckregion 86 not being tapered, and so forth). However, such geometricalrelationships are intended to be within the scope of the presentdisclosure. The internal vent path 120 instead includes, moving fromleft (the first side 70) to right (the second side 72), a first portion122, a second portion 124, and a third portion 126 all having geometriesthat are different from one another.

The first portion 122, as depicted, has a generally unchanging geometryand extends from the rear face 104, through the elbow portion 106 andthe annular neck region 78, and terminates at a transition 128 betweenthe annular neck region 78 and the obround neck region 86. The firstportion 122 of the internal vent path 120 may generally have anygeometry, and in the illustrated embodiment has an annular geometry witha substantially unchanging diameter. However, in other embodiments, thefirst portion 122 may be tapered, may have a different shape (e.g.,obround, square), or a combination thereof.

As depicted, the second portion 124 has a position corresponding to aportion of the obround neck region 86, and is generally smaller in sizerelative to the first and third portions 122, 126. The second portion124 may be annular or elliptical, or any other shape, and may or may notbe tapered. In the illustrated embodiment, the second portion 124 has ataper 130, the degree of which may depend on the relative sizes of thefirst, second, and third portions 122, 124, 126, desired effect on thevented gases, or any combination thereof. In embodiments where the taper130 is obround (e.g., elliptical), the taper 130 may be along only theminor diameter of the second portion 124, only along the major diameterof the second portion, or along both the minor and major diameters ofthe second portion 124.

Regarding the size of the second portion 124 relative to the firstportion 122, the second portion 124 may have a surface area taken at anypoint along its axial length (along the direction illustrated by arrow120) that is between approximately 10% and 90% of the surface area ofthe first portion 122. By way of non-limiting example, the taper 130 maybe such that the surface area of the second portion 124 varies from afirst percentage to a second percentage of the surface area of the firstportion 122, the first percentage being between approximately 10% andapproximately 60%, and the second percentage being between approximately20% and 90%.

Though the taper 130 of the second portion 124 may be of any degree, itmay be desirable for the taper 130 to be such that an upstream end 131of the second portion 124 has a surface area that is betweenapproximately 50% and approximately 95% of the surface area of adownstream end 132 of the second portion 124. Further, in someembodiments, the downstream end 132 may have a surface area that issmaller than the surface area, taken at a point along its length, of thefirst portion 122.

The internal vent path 120 transitions from the second portion 124 tothe third portion 126 within the obround neck region 86, as illustrated.However, it should be noted that this transition may occur at otherlocations, such as at the lip portion 84, or any other location (e.g.,closer to the second side 72 than the first side 70). The third portion126 may have any geometry, such as obround, annular, or the like. In theillustrated embodiment, the third portion 126 is obround (e.g.,elliptical) and is generally larger in size (e.g., as measured by thesurface area of the portions at a point along their length) than thesecond portion 124. The third portion 126 may or may not be tapered. Asdepicted, the third portion 126 includes a taper 132 that causes anincrease in the minor diameter of the third portion 126 along itslength. In certain embodiments, the taper 132 may also increase themajor diameter of the third portion 126 along its length. Indeed, ingeneral, the taper 132 may increase the major and/or minor diameters ofthe third portion 126 along its length.

Again, the adapter 50 discussed above with respect to FIGS. 3-7 may beparticularly useful for enabling a group 65 battery to be used in agroup 66 battery application by enabling the vent port 40 of the group65 battery to couple with the vent hose 60 of a group 66 batteryapplication. In this regard, the present embodiments also relate toother group batteries having other vent port geometries and solves othertechnical problems. Another embodiment and associated application of theadapter 50 is depicted schematically in FIG. 8 . Specifically, theembodiment of the adapter 50 depicted in FIG. 8 may be configured toenable an embodiment of the battery 12, such as a BCI group 24F battery,to have a locking key venting configuration.

As depicted in FIG. 8 , the embodiment of the battery 12 (e.g., a group24 F battery) includes the vent port 40 formed in the cover 38 in asimilar manner as set forth above with respect to the group 65 batteryexample described above. Indeed, as with the group 65 battery, theillustrated battery 12 of FIG. 8 includes an embodiment of the vent port40 having a DIN-style 6 mm opening, which has a circular geometry 62.However, it is presently recognized that group 24F batteries such asthese may also be appropriate for use in other applications where a venttube may not be compatible with the vent port 40. For example, such agroup 24F battery may be able to be used in another application thatrequires a locking key vent configuration 140, such as shown on theright side of FIG. 8 .

In accordance with certain embodiments of the present disclosure, theadapter 50 may have a configuration that enables a first matedrelationship with the vent port 40 having the circular/annular geometry62, and a second mated relationship with a keyed vent tube 142. Thekeyed vent tube 142 may be considered to be keyed due to the inclusionof a protrusion 144 having a particular geometry that appropriatelymates with a corresponding female connector. However, it is also withinthe scope of the present disclosure for the protrusion 144 to instead beon the adapter 50 and the female connector portion to be on the venttube.

As illustrated, the embodiment of the adapter 50 includes an embodimentof the first side 70 having a geometry generally configured tocorrespond with the geometry of the vent port 40. For example, the firstside 146 may include an embodiment of the vent port interface surface 74and an embodiment of the annular neck region 78, both of which mayinterface with the vent port 40 so as to enable an interference fit withthe vent port 40. Indeed, the vent port interface surface 74 and theannular neck region 78 of FIGS. 8-11 may be configured in a similarmanner and have generally the same geometric relationships with the ventport 40 and one another as set forth above with respect to the adapter50 of FIGS. 3-7 . In this way, the description associated with the ventport interface surface 74 and the annular neck region 78 illustrated inFIGS. 3-7 is also intended to be applicable to their counterparts shownin FIGS. 8-11 , where appropriate.

The embodiment of the adapter 50 in FIGS. 8-11 may also include anembodiment of the elbow portion 106 positioned at the interface betweenthe vent port interface surface 74 and the annular neck region 78, whichmay also have a similar configuration as set forth above with respect toFIGS. 3-7 . The elbow portion 106 may, in certain embodiments, have asize that is substantially matched to the size of the circular geometry62 (e.g., 6 mm in diameter) such that the elbow 106 at least partiallycauses the adapter 50 to be secured within the vent port 40 by afriction/interference fit. It should also be noted that in certainembodiments, there may be no elbow 106 for the adapter 50 of FIGS. 3-7or FIGS. 8-11 , and the taper 76 may instead extend from the rear end104 of the adapter 50 and to an upstream end 146 of the annular neckregion 78. The upstream end 146 can be more clearly seen in FIG. 10 .

Unlike the adapter 50 of FIGS. 3-8 , the embodiment of the adapter 50 inFIGS. 8-11 includes an ovoid body 148 having a cross-sectional geometryof an oval extending from the upstream end 146 of the annular neckregion 78 and to an embodiment of the front face 83. However, it is alsowithin the scope of the present disclosure for the ovoid body 148 toinstead be an annular shape or some other polygonal, curved, or complexgeometry. Indeed, the ovoid body 148 (or variations thereof) may only berequired to enable housing of the connection features described below.However, it is presently recognized that the form factor of the ovoidbody 148 may generally correspond to the internal connection features tosave materials and correspondingly reduce costs, size, weight, and thelike.

In further contrast to the embodiment of the adapter 50 of FIGS. 3-8 ,the adapter 50 of FIGS. 8-11 does not have a male mating connector onthe second side 72, but instead has a female mating connector 150configured to receive the keyed vent tube 142. The ovoid body 148 may beof any size appropriate to enable the formation of the female matingconnector 150 and its associated features. For example, the keyed tube142 may have a diameter of its curved portion of approximately 8 mm, andone or more portions of the female mating connector 150 may have a sizethat is substantially matched (e.g., a curved portion having a diameterof approximately 8 mm).

Specifically, the female mating connector 150 of the adapter 50 may beconsidered to define or include an internal portion of the adapter 50that is configured to hold the keyed vent tube 142. The illustratedfemale mating connector 150 includes a keyed region 152 having aspecific geometry corresponding to the keyed configuration of the keyedvent tube 142. The keyed region 152 has a complex surface in which acurve 154, represented as an arc having an arc angle of less than 360degrees (e.g., between approximately 300 degrees and approximately 350degrees), is joined at its ends by a second geometry to form a keyopening 156, which may have a cross-sectional appearance of a square,rectangle, triangle, or other polygon, or another curved shape.Generally, the surface area defined by the second geometry of the keyopening 156 will be smaller than the surface area defined by the curve154, and the keyed region 152 will have a shape that is substantiallythe same as the keyed vent tube 142.

As shown in FIGS. 8, 10, and 11 , the ovoid body 148 does not have achanging size along its length (e.g., does not have a taper in the axialdirection of the adapter 50). However, the female mating connector 150may include internal features having a taper or other features to enablea secure fit with the keyed vent tube 142. For example, as shown in thefront view of FIG. 9 and the cross-sectional side view of FIG. 11 , thekeyed region 152 includes a stepped configuration in which an additionalcurve 160 is disposed within the internal vent path 120 of the adapter50, and the additional curve 160 has a smaller cross-sectional surfacearea compared to the curve 154. The arc angle of the additional curve160 may be the same or different than the curve 154, but in theillustrated embodiment is substantially the same. This can be seen as asmall decrease in the size of the female mating connector 150, whichforms a step 162, in FIGS. 8, 9, and 11 . Another step 164 can be seenin FIGS. 9 and 11 , which corresponds to a transition between anembodiment of the first and second portions 122, 124 of the internalvent path 120 of the adapter 50.

Referring now to the cross-sectional side view of FIG. 11 , theembodiments of the first, second, and third portions 122, 124, 126 ofthe internal vent path 120 are illustrated as having generallyincreasing cross-sectional surface areas moving from the first side 70to the second side 72. As shown, the first, second, and third portions122, 124, 126 of the internal vent path 120 provide an incrementalincrease in the size of the internal vent path 120.

The sizes of the second and third portions 124, 126 are also configuredto facilitate securement of the keyed vent hose 142. For example, thethird portion 126 in FIG. 11 may be sized to enable the keyed vent hose142 to be inserted into the female mating connector 150 with a first,relatively low application force while also requiring the protrusion 144to be positionally matched with the key opening 156. In this way, theprotrusion 144 and the key opening 156 cause the keyed vent tube 142 andthe adapter 50 to have a predetermined orientational relationship inorder to appropriately form a mated connection (e.g., via aninterference fit). Thus, the third portion 126 may have across-sectional geometry that is larger (e.g., between approximately0.1% larger and approximately 10% larger) than the cross-sectionalgeometry of the keyed vent tube 142, as determined by the size of thecurve 154 and the key opening 156. In this and/or other embodiments, thethird portion 126 may be substantially matched in size to the keyed venttube 142.

To continue inserting the keyed vent tube 142 into the second portion124, a second insertion force, greater than the first insertion force,may be required by virtue of the size of the second portion 124 relativeto the keyed vent tube 142. Thus, in some embodiments, the secondportion 124 may have a cross-sectional geometry that is substantiallymatched to, or smaller than, the cross-sectional geometry of the keyedvent tube 142. By way of non-limiting example, the cross-sectionalsurface area of the second portion 124 may be between approximately 90%and approximately 99% of the cross-sectional surface area of the keyedvent tube 142.

While the first portion 122 of the internal vent path 120 of FIG. 11 hassubstantially the same geometric configuration as set forth above withrespect to the first portion 122 of FIG. 7 , the first portion 122 ofFIG. 11 extends from the rear face 104 and into a section of theinternal vent path 120 corresponding to the ovoid body 148. The secondportion 124 and the third portion 126, as shown, extend for theremainder of the internal vent path 120.

Configurations for the internal vent paths 120 other than thoseexplicitly shown in FIGS. 7 and 11 are also possible and are consideredto be within the scope of the present disclosure. For example, theinternal vent path 120 may include only one portion, only two portions,or three or more portions. Each portion of the internal vent path 120may have any geometry, may or may not have a taper, and may have anysize relative to the external geometry of the adapter 50. However, it ispresently recognized that the configurations specifically illustratedand described herein may have certain benefits and solve technicalissues that may not necessarily be addressed by other configurations.

Further, other configurations for the outer geometries of the adapter 50are also within the scope of the present disclosure. For example, asillustrated in FIGS. 12 and 13 , certain embodiments of the adapter 50may be configured to enable a change in venting position of certainbatteries. Specifically, the embodiments illustrated in FIGS. 12 and 13include a battery system 180 having multiple batteries 12 of aparticular BCI group (e.g., group 31 batteries), each of the batteries12 having the same location for their respective vent ports 40. Thegroup 31 batteries 12, as illustrated, all have their respective ventports 40 positioned proximate their respective third electrochemicalcell 182, which corresponds in position to the third circle from thebottom of FIG. 12 .

In certain applications, the batteries 12 may all be secured within avehicle using, among other things, a hold down bar 184 or similarfeature placed over the covers 38 of the batteries 12. As illustrated,the hold down bar 184 may span across all of the batteries 12 atsubstantially the same position as the vent ports 40, which may createdifficulty in connecting vent tubes 186 due to spatial constraints.

In accordance with an aspect of the present embodiments, the illustratedembodiment of the adapter 50 of FIGS. 12 and 13 may couple to the ventport 40 of one of the batteries 12, may extend from the vent port 40 ina first direction 188, and may turn to enable vented gases to bedirected in a second direction 190. The second direction 190 maygenerally be considered to be crosswise relative to the first direction188 (e.g., perpendicular), and may turn in a direction other than thedirection illustrated in FIG. 13 .

The adapter 50 of FIGS. 12 and 13 has a first portion 192 correspondingto the first direction 188, and a second portion 194 corresponding tothe second direction 190, where the first portion 192 is disposed on thefirst side 70 that mates with the vent port 40, and the second portion194 is disposed on the second side 72 that mates with a vent tube 196(the full tube is not shown). The first and second portions 192, 194 mayinclude, independently (i.e., they may be the same or different), femaleor male connectors. The first portion 192 is configured to fit over andmate with the vent port 40 of the battery 12 (e.g., via afriction/interference fit). The illustrated vent ports 40 include aprotrusion and associated opening for venting gases from the battery 12.Depending on its size relative to the vent tube 196, the second portion194 may fit over and mate with the vent tube 196 as a female connector,or may be insertable into the vent tube 196 as a male connector. In thisregard, the first portion 192, the second portion 194, or a combinationthereof, of the adapter 50 of FIGS. 12 and 13 may include any one or acombination of the internal and external geometric features andrelationships set forth above with respect to the adapters in FIGS. 3-11. In certain configurations, for example, the first portion 192 and thesecond portion 194 may be different geometric shapes.

In the illustrated embodiment, the adapter 50 may be sized so as to fitwithin a tolerance 198 (e.g., an opening or crevice) disposed betweenthe respective covers 38 of adjacent batteries 12. This may enable theadapter 50 to fit on the vent ports 40 on the first side 70 and coupleto vent tubes that are not capable of being appropriately (e.g.,optimally) fitted directly onto the vent ports 40 due to a lack ofavailable space. Specifically, the first portion 192 may be sized so asto extend into the tolerance 198, and the second portion 194 may besized so as to extend within the tolerance 198 in an appropriatedirection (e.g., the second direction 190). In certain embodiments, thesize of the adapter 50 enables gases to be vented off of a fourthelectrochemical cell 200, which generally corresponds in position to thefourth circle from the bottom of FIG. 12 .

One or more of the disclosed embodiments, alone or on combination, mayprovide one or more technical effects useful in the production,installation, and use of lead-acid batteries for multiple applications.For example, certain embodiments of the present approach may enablereduced costs associated with the manufacture of batteries, such as byreducing or eliminating the need for different battery groups whose maindifference is the position and/or geometry of their venting mechanisms.In addition, certain embodiments of the present approach also enablecertain batteries, heretofore suitable for only a single application, tobe suitable for more than one application by enabling a single groupbattery to be compatible with the requirements of other battery groups(e.g., BCI groups). The technical effects and technical problems in thespecification are examples and are not limiting. It should be noted thatthe embodiments described in the specification may have other technicaleffects and can solve other technical problems.

While only certain features and embodiments of the invention have beenillustrated and described, many modifications and changes may occur tothose skilled in the art (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters (e.g., temperatures, pressures, etc.), mounting arrangements,use of materials, colors, orientations, etc.) without materiallydeparting from the novel teachings and advantages of the subject matterrecited in the claims. The order or sequence of any process or methodsteps may be varied or re-sequenced according to alternativeembodiments. It is, therefore, to be understood that the appended claimsare intended to cover all such modifications and changes as fall withinthe true spirit of the invention. Furthermore, in an effort to provide aconcise description of the exemplary embodiments, all features of anactual implementation may not have been described (i.e., those unrelatedto the presently contemplated best mode of carrying out the invention,or those unrelated to enabling the claimed invention). It should beappreciated that in the development of any such actual implementation,as in any engineering or design project, numerous implementationspecific decisions may be made. Such a development effort might becomplex and time consuming, but would nevertheless be a routineundertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure, without undueexperimentation. Further, although individual embodiments are discussedherein, the disclosure is intended to cover all combinations of theseembodiments.

The invention claimed is:
 1. A battery system, comprising: a lead-acidbattery comprising: a housing; a plurality of lead-acid battery cellsdisposed within the housing; a vent port in the housing configured tovent gases evolved from the plurality of lead-acid battery cells; a ventadapter fitted to the lead-acid battery, and configured to fluidlycouple the vent port with a vent connector having a different geometricshape, comprising: a first connector, comprising a vent port interfacesurface connected to a tapered annular neck at an elbow in the firstconnector, substantially matched in shape and size with the vent port toenable an interference fit between the vent port and the firstconnector; and a second connector having a different shape than the ventport of the lead acid battery; and the lead-acid battery has a firstbattery group designation, and the second connector is substantiallymatched in shape and size with a different vent port of a second batterygroup designation so as to mimic the different vent port of anotherlead-acid battery having the second battery group designation.
 2. Thebattery system of claim 1, wherein the first battery group designationis BCI group 65 and the second group designation is BCI group
 66. 3. Thebattery system of claim 1, wherein the first battery group designationis BCI group 24F, and the second connector comprises a keyed receptacleconfigured to receive and form an interference fit with a keyed venttube.
 4. The battery system of claim 1, wherein the first and secondbattery group designations have maximum dimension requirements withinapproximately 10% of one another.
 5. The battery system of claim 1,comprising a kit having the lead-acid battery and the vent adapter. 6.The battery system of claim 1, wherein the first connector has an outersurface geometry that is shaped and sized to be inserted into and matewith the vent port in the interference fit.
 7. The battery system ofclaim 1, wherein the second connector has an outer surface geometryshaped and sized to be inserted into and mate with the vent connector inan interference fit.
 8. The battery system of claim 1, wherein thesecond connector comprises a female mating connector comprising a keyedregion, the keyed region comprising a curve with an arc angle of lessthan 360 degrees and joined at its ends by a second geometry to form akey opening.
 9. The battery system of claim 1, wherein the vent adapterfurther comprises: a first portion having a first cross-sectionalsurface area; a second portion having a second cross-sectional surfacearea greater than the first cross-sectional surface area; and a thirdportion having a third cross-sectional surface area greater than thesecond cross-sectional surface area.
 10. A battery system, comprising: alead-acid battery having a vent port; a vent adapter mated to the ventport in an interference fit and having a connector configured to fluidlycouple the lead acid battery with a vent connector via an internal ventpath to flow vented gasses from a first side of the vent adapter to asecond side of the vent adapter, with the vent connector having adifferent geometric shape than the vent port, and the internal vent pathcomprising a first portion having a first cross-sectional surface area,a second portion having a second cross-sectional surface area greaterthan the first cross-sectional surface area, and a third portion havinga third cross-sectional surface area greater than the secondcross-sectional surface area; and the lead-acid battery has a firstbattery group designation, and the connector is substantially matched inshape and size with a vent connector associated with a second batterygroup designation so as to mimic the different vent port of anotherlead-acid battery having the second battery group designation.
 11. Thebattery system of claim 10, wherein the first battery group designationis BCI group 65 and the second group designation is BCI group
 66. 12.The battery system of claim 10, wherein the first battery groupdesignation is BCI group 24F, and the connector comprises a keyedreceptacle configured to receive and form an interference fit with akeyed vent tube.
 13. The battery system of claim 10, comprising the ventconnector attached to the connector of the vent adapter.
 14. The batterysystem of claim 10, wherein the second side of the vent adapter furthercomprises a female mating connector comprising a keyed region, the keyedregion comprising a curve with an arc angle of less than 360 degrees andjoined at its ends by a second geometry to form a key opening.
 15. Abattery system, comprising: a lead-acid battery installed within avehicle, comprising: a housing; a plurality of lead-acid battery cellsdisposed within the housing and being electrically coupled to thevehicle via two or more terminals of the lead-acid battery; and a ventport in the housing, the vent port being fluidly coupled to a ventpassage of the vehicle via an interference fit with a vent adapter,wherein the vent adapter is directly coupled to the vent port at a firstend and is directly coupled to the vent passage of the vehicle at asecond end, and the first and second ends of the vent adapter haverespective different cross-sectional geometric shapes, and wherein thesecond end further comprises a female mating connector in communicationwith a keyed region, the keyed region comprising a curve with an arcangle of less than 360 degrees and joined at its ends by a secondgeometry to form a key opening.
 16. The battery system of claim 15,wherein the first and second ends of the vent adapter comprise outersurface geometries mated via respective interference fits with the ventport and vent passage.
 17. The battery system of claim 15, wherein thefirst end of the vent adapter comprises an outer surface geometry matedvia first interference fit with the vent port and the second end of thevent adapter comprises an inner surface geometry mated via a secondinterference fit with the vent passage.
 18. The battery system of claim15, comprising an additional lead-acid battery disposed proximate thelead acid battery, the lead-acid battery and the additional lead-acidbattery being secured within the vehicle using at least a hold down barextending across respective covers of the lead-acid batteries, the ventport of the lead-acid battery being positioned proximate the position ofthe hold down bar, wherein the vent adapter comprises a first portionhaving the first end and extending away from the lead-acid battery andtoward the additional lead-acid battery in a first direction, and thevent adapter comprises a second portion having the second end and acrosswise axial orientation relative to the first portion, and whereinthe second portion extends along an available space between therespective covers of the lead-acid battery and the additional lead-acidbattery and generally away from the hold down bar.